Method for Functionalization of Nanoscale Fiber Films

ABSTRACT

Methods are provided for functionalizing a macroscopic film comprised of nanoscale fibers by controlled irradiation. The methods may include the steps of (a) providing a nanoscale fiber film material comprising a plurality of nanoscale fibers (which may include single wall nanotubes, multi-wall nanotubes, carbon nanofibers, or a combination thereof); and (b) irradiating the nanoscale fiber film material with a controlled amount of radiation in the open air or in a controlled atmosphere. The step of irradiating the nanoscale fiber film material is effective to functionalize the plurality of nanoscale fibers. Irradiated nanoscale fiber films are also provided having improved mechanical and electrical conducting properties.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional of U.S. patent application Ser. No. 11/749,302, filed May 16, 2007. Priority benefit of U.S. Provisional Application No. 60/747,343, filed May 16, 2006, is claimed. These prior applications are incorporated herein by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with U.S. government support under Award No. FA9550-05-1-0271 awarded by the Air Force Office of Scientific Research. The U.S. government has certain rights in the invention.

BACKGROUND OF THE INVENTION

This invention is generally in the field of nanoscale fiber film materials, and more particularly in the field of materials comprising functionalized nanotubes, other functionalized nanoscale fibers, and the like.

Nanoscale fiber film materials are used in various applications such as high performance filtration membranes, battery and fuel cell electrodes, electromagnetic interference (EMI) shielding, and composite materials of construction. Unfortunately, the use of nanoscale fiber film materials may be limited in some instances by their mechanical properties, which may include a low tensile modulus and a low tensile strength. It would therefore be useful to provide a method for substantially increasing the strength of nanoscale fiber films.

Conventional methods of treating fiber films, such as oxidation and fluorination processes, typically may involve multiple, time-consuming steps, which unfortunately may result in a low product yield, due to the size and chemical nature of nanoscale fibers. Furthermore, these conventional methods may include intense chemical reactions, long stirring times, multiple washings, and/or other steps that can shorten, dissolve, or even destroy the nanotube or nanofibers of the nanoscale material, as well as damage the integrity of the nanoscale fiber film. Accordingly, the mass production of nanoscale fiber films treated with conventional methods is difficult at best. It would therefore be useful to provide new and improved methods for treating nanoscale fiber films that may be carried out rapidly and effectively, while maintaining the integrity of the nanoscale fiber film.

SUMMARY OF THE INVENTION

In one aspect, methods are provided for functionalizing nanoscale fiber films. In one embodiment, the method may include the steps of: (a) providing a nanoscale fiber film material which comprises a plurality of nanoscale fibers; and (b) irradiating the nanoscale fiber film material with a controlled amount of radiation. The step of irradiating the nanoscale fiber film material may increase the tensile strength and modulus of the nanoscale fiber film material, increase the toughness of the nanoscale fiber film material, increase the electrical and thermal conductivity of the nanoscale fiber film material, or may increase a combination of these properties.

In a preferred embodiment, the step of irradiating the nanoscale fiber film material is effective to functionalize the plurality of nanoscale fibers. The step of irradiating the nanoscale fiber film material may create cross-links, interconnections, junctions, or a combination thereof, in the plurality of nanoscale fibers. The irradiation step also may increase interfacial bonding in the plurality of nanoscale fibers.

In one embodiment, the step of irradiating the nanoscale fiber film material may utilize an electron beam. The electron bean may irradiate the nanoscale fiber film material at about 2 MeV, and may apply a dose of electrons in the range from about 10×10¹⁵ to about 300×10¹⁵ e/cm². In another embodiment, the step of irradiating the nanoscale fiber film material may include applying an ion particle beam to the nanoscale fiber film material. In yet another embodiment, the step of irradiating the nanoscale fiber film material may include applying an ultra-violet beam to the nanoscale fiber film material.

In one embodiment, the step of providing the nanoscale fiber film material includes the steps of: (a) suspending the plurality of nanoscale fibers in a liquid medium; and (b) removing the liquid medium by at least one of filtration or vaporization to form the nanoscale fiber film material. The nanoscale fiber film material preferably may have a thickness in the range from about 5 to about 50 microns. The plurality of nanoscale fibers preferably includes a plurality of carbon nanotubes.

In another aspect, a functionalized nanoscale fiber film material is provided. Preferably, the functionalized nanoscale fiber film material include a plurality of nanoscale fibers functionalized by a controlled irradiation process. The functionalized nanoscale fiber film material may have, relative to a non-irradiated nanoscale fiber film material of the same construction, increased tensile strength, increased toughness, increased electrical and thermal conductivity, or a combination thereof.

The nanoscale fiber film material may have a plurality of cross-links, interconnections, junctions, or a combination thereof, between or among the plurality of nanoscale fibers. In one embodiment, the nanoscale fiber film material may have a thickness in the range from about 5 to about 50 microns and the plurality of nanoscale fibers may include a plurality of carbon nanotubes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional, perspective view illustrating a certain embodiment of a nanoscale fiber film material in which nanotubes are cross-linked with cross-links formed by an irradiation process.

FIG. 2 is a graph which shows a stress-strain curve of a nanoscale fiber film material after receiving various doses of irradiation.

FIG. 3 is a graph which shows tensile strength of a nanoscale fiber film material after receiving various doses of irradiation.

DETAILED DESCRIPTION OF THE INVENTION

Methods have been developed for functionalizing nanoscale fiber film materials by treating a nanoscale fiber film with an irradiation process to effectively and quickly functionalize the film. Unlike conventional chemical methods of functionalizing nanoscale fiber films, which may be time consuming, damaging, and inefficient, the instant methods utilize high penetration and efficiency of energetic beam irradiation and advantageously may avoid or minimizes the problems associated with conventional chemical treatment techniques. For instance, the irradiation process may eliminate the need to use any chemical or washing processes, and may require only a short processing time. Furthermore, because the yield rate this method is almost 100%, the process has excellent potential for low cost mass production. The present methods may be rapidly performed, provide effective functionalization, and maintain film integrity.

As used herein, the terms “comprise,” “comprising,” “include,” and “including” are intended to be open, non-limiting terms, unless the contrary is expressly indicated.

The Nanoscale Fiber Film

The process can be used on essentially any nanoscale fiber film. As used herein, the term “nanoscale fiber film” refers to a thin, macroscopic sheet composed of many nanoscale fibers dispersed in a network, and the term “nanoscale fibers” refers to a thin, greatly elongated solid material, typically having a cross-section or diameter of less than 500 nm. The nanoscale fibers may comprise carbon nanoscale fibers or, potentially, other inorganic nanoscale fibers.

In a particular embodiment, the nanoscale fibers comprise carbon nanoscale fibers such as single walled carbon nanotubes (SWNTs), multiple-walled carbon nanotubes (MWNTs), carbon nanofibers (CNFs), or mixtures thereof SWNTs typically have small diameters (˜1-5 nm) and large aspect ratios, while MWNTs typically have large diameters (˜5-200 nm) and small aspect ratios. CNFs are filamentous fibers resembling whiskers of multiple graphite sheets. As used herein, the term “carbon nanotube” refers to carbon fullerene, a synthetic graphite, which typically has a molecular weight of between about 840 and about 10 million or more. Carbon nanotubes are commercially available, for example, from Carbon Nanotechnologies, Inc. (Houston, Tex.), or can be made using techniques known in the art. In a preferred embodiment, the nanoscale fibers comprise or consist of carbon nanotubes, including both SWNTs and MWNTs (multiple-walled carbon nanotubes).

The nanoscale fibers optionally may be chemical modified or coated with other materials such as metals. The nanotubes optionally may be opened or chopped, for example, as described in U.S. Patent Application Publication No. 2006/0017191 A1, which is incorporated herein by reference.

The nanoscale fiber film may be fabricated by suspending nanoscale fibers in a liquid, and then removing the liquid to form a film. For example, the films can be fowled by dispersing nanotubes in water to form suspensions, and then filtering or vaporizing the suspensions to form the film.

The nanoscale fibers in the film can be randomly dispersed or aligned. An aligned nanoscale fiber film may be prepared, for example, using in situ filtration of a suspension in a high strength magnetic field, as described in U.S. Patent Application Publication No. 2005/0239948 to Haik et al., which is incorporated herein by reference.

In one embodiment, the nanoscale film is from 5 to 50 microns thick with a typical area density of 0.0705 oz/ft² (or 21.5 g/m²) or greater.

The Methods

The methods of nanoscale fiber film functionalization include an irradiation step. In a preferred embodiment, the method includes (a) providing a nanoscale fiber film material comprising a plurality of nanoscale fibers; and (b) irradiating the nanoscale fiber film material in open air or in a controlled environment, such as an Argon gas atmosphere, with an amount of radiation effective to functionalize the plurality of nanoscale fibers.

The nanoscale film is irradiated with an amount of radiation effective to functionalize the nanoscale film. The terms “functionalization” and “functionalize” refer to the creation of cross-links, vacancies, knock-on carbon atoms, or pentagon/heptagon Stone-Wales defects, as well as various interconnections or junctions, in and/or among the nanoscale fibers, or to another alteration that changes one or more mechanical and other physical and/or chemical properties of the nanoscale fiber film relative to that of a non-irradiated nanoscale fiber film. Non-limiting examples of these mechanical properties include strength, tensile strength, toughness, and strain resistance. The irradiation process may increase interfacial bonding in the film. FIG. 1 shows one example of how a plurality of nanotubes 10 may be joined together by cross-links 20 formed between the nanotubes 10 by irradiating a nanoscale fiber film material.

The irradiation process is controlled. That is, the step of irradiating the nanoscale fiber film material is performed in a controlled (i.e., selective and measured) manner so that a controlled amount of radiation is applied to the nanoscale fiber film. This is not the uncontrolled irradiation that may occur from the random exposure to environmental radiation from natural sources (e.g., sunlight) and man-made sources (e.g., lighting, communication, and other devices). The irradiation process may be conducted with a controlled application of an energetic beam, such as an electron beam, an ion particle beam, or an ultraviolet (UV) light beam, using techniques and equipment known in the art. For example, an irradiation dose of electron beam treatment can be in a large range and as high as 2×10²² e/cm². For ion particle beam irradiation, incident energies of light ions as low as 50 eV can lead to nanotube crosslink. Significant improvement of electrical conductivity and Young modulus of SWNTs also have been reported. Using no more than routine experimentation, one skilled in the art readily can determine the relationship between the irradiation intensity, the degree of functionalization, and the mechanical properties of the film. Based on such results, an appropriate dose or duration of irradiation can be determined. In a particular embodiment, the irradiation is conducted with an electron beam, and the electron beam irradiates that nanoscale fiber film with a dose of electrons in the range from about 10×10¹⁵ to about 300×10¹⁵ e/cm².

The degree of functionalization can be tailored by adjusting the irradiation intensity. The irradiation intensity can be adjusted by selecting the acceleration voltage, current, and exposure time. In a particular embodiment, the irradiation is carried out at about 2 MeV. The irradiation may take place while the nanoscale fiber film material is on a cooled plate. In addition, using a commercialized irradiation facility, such as the 5 MeV electron beam facility at Kent State University/Mercury Plastics Inc. (Cleveland, Ohio), the functionalization process may be continuous and scaled up for mass production.

The functionalized nanoscale fiber films may be used in a wide variety of applications. In particular, films with improved mechanical properties are highly desirable in filtration membranes, battery electrodes, fuel cell electrodes, EMI shielding, and composite material applications. In addition, the functionalized nanoscale films may be used in applications requiring highly pure materials, or in applications needing porous nanoscale films. The flexibility and strength of the functionalized nanoscale film facilitates easy handling, and may allow for the incorporation of the nanoscale materials into a variety of composite materials of construction. These composite materials of construction may be used in high strength, lightweight structural members (e.g., for automotive body parts, athletic equipment, aircraft, and spacecraft), nanoelectronics, fuel cells, optical equipment, and video displays (e.g., field emission displays). Nanotube-metal matrix materials also can be used to make extremely strong structural materials for aircraft, spacecraft, power-transmission lines, and suspension bridges.

The Functionalized Film

The nanoscale fiber film material comprises a plurality of nanoscale fibers. In a particular embodiment, the plurality of nanoscale fibers are functionalized with an irradiation process. As a result of the irradiation process, the nanoscale fiber film material may have at least one improved mechanical property. For example, the nanoscale fiber film may have increased tensile modulus, increased tensile strength, increased toughness, or increased strain resistance. In a preferred embodiment, the nanoscale fiber film material has a thickness in the range from about 5 to about 50 microns.

The plurality of nanoscale fibers may comprise carbon nanoscale fibers, inorganic nanoscale fibers, or both. In a particular embodiment, the nanoscale fibers comprise carbon nanoscale fibers such as single walled carbon nanotubes (SWNTs), multiple-walled carbon nanotubes (MWNTs), carbon nanofibers (CNFs), or mixtures thereof. The plurality of nanoscale fibers may have at least one feature such as cross-links, vacancies, knock-on carbon atoms, or Stone-Wales defects, as well as interconnections or junctions, created with the irradiation process.

The functionalized nanoscale fiber film may be included as part of a multi-component structure. In one case, the functionalized nanoscale fiber film is part of a laminate. For example, one or more layers of the functionalized nanoscale film may be layered with one or more layers of a second material. The second material may be a polymer, a ceramic, a metal, a glass, or a semi-conductor. The second material may be monolithic or fibrous. An adhesive material optionally may be included in the laminate, for example to secure the various layers together. In another case, the functionalized nanoscale fiber film is part of a unitary composite. For example, the unitary composite may include a functionalized nanoscale fiber film dispersed in a matrix material. For example, the matrix material may be a polymer, a metal, or a glass. The matrix material may be a thermoplastic material that is combined in its liquid state with a nanoscale fiber film and then solidified. The nanoscale fiber film may be functionalized before or after combination with other components of the multi-component structure, depending for example on the other materials construction, location, and/or thickness.

The methods and materials described above will be further understood with reference to the following non-limiting examples.

EXAMPLE 1 Electron Beam Irradiation of SWNT Film

SWNTs were obtained from Carbon Nanotechnologies Inc. (Houston, Tex.). The nanotubes were P-Grade purified SWNTs with an average diameter of about 1 to about 1.2 nm and an average length of about 200 to about 500 nm.

Nanotube films were prepared from the SWNTs as follows: The SWNTs were dispersed with sonification into distilled water containing Triton X-100 surfactant in order to form a stable suspension. The SWNT concentration in the suspension was 40 mg/L. Next, about 12 to 15 liters of suspension was filtered using a custom-made filter with a 0.45 μM nylon filter membrane from Millipore, Inc. (Billerica, Mass.). The filtration process yielded a SWNT film (i.e., a sheet or membrane). The film was then washed using isopropanol. The length and width dimensions of the SWNT film were about 9 inches by 9 inches.

The film was cut into 2 inch by 3 inch pieces for the irradiation. E-beam irradiation of the SWNT films was conducted using an electron accelerator at Kent State University/Mercury Plastics, Inc. (Middlefield, Ohio). During the irradiation, the SWNT films were placed directly on basement plates, which were cooled with circulated water. Samples were irradiated at 2 MeV for various times in open air in order to achieve the desired E-beam doses. The doses were 9×10¹⁵, 93×10¹⁵, 139×10¹⁵, 186×10¹⁵, and 281×10¹⁵ e/cm².

The irradiated SWNT sheets were cut into 4 mm wide and 25 mm long strips, and tested with a DMA (dynamic mechanical analyzer) machine (DMA2980, TA Instruments, New Castle, Del.) using the stress-strain sweeping mode. Stress, strain, and tensile strength tests were conducted on a control (non-irradiated) film and on the irradiated films. As shown in FIG. 2, the mechanical properties of the SWNT films were significantly improved as the dose of E-beam irradiation was increased. FIG. 3 shows the increase in tensile strength as a result of the E-beam dose.

Publications cited herein and the materials for which they are cited are specifically incorporated by reference. Modifications and variations of the methods and materials described herein will be obvious to those skilled in the art from the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims. 

1. A method of functionalizing a nanoscale fiber film material, comprising the steps of: (a) providing a nanoscale fiber film material which comprises a plurality of nanoscale fibers; and (b) irradiating the nanoscale fiber film material with a controlled amount of radiation, wherein the radiation comprises an ion-particle beam or ultra-violet beam.
 2. The method of claim 1, wherein the step of irradiating the nanoscale fiber film material is effective to functionalize the plurality of nanoscale fibers.
 3. The method of claim 1, wherein the step of irradiating the nanoscale fiber film material increases the tensile strength and modulus of the nanoscale fiber film material.
 4. The method of claim 1, wherein the step of irradiating the nanoscale fiber film material increases the toughness of the nanoscale fiber film material.
 5. The method of claim 1, wherein the step of irradiating the nanoscale fiber film material increases the electrical and thermal conductivity of the nanoscale fiber film material.
 6. The method of claim 1, wherein the step of irradiating the nanoscale fiber film material creates cross-links, interconnections, junctions, or a combination thereof, in the plurality of nanoscale fibers.
 7. The method of claim 1, wherein the step of irradiating the nanoscale fiber film material increases interfacial bonding in the plurality of nanoscale fibers.
 8. The method of claim 1, wherein the step of providing the nanoscale fiber film material comprises: (a) suspending the plurality of nanoscale fibers in a liquid medium; and (b) removing the liquid medium by at least one of filtration and vaporization to form the nanoscale fiber film material.
 9. The method of claim 1, wherein the nanoscale fiber film material has a thickness in the range from about 5 to about 50 microns.
 10. The method of claim 1, wherein the plurality of nanoscale fibers comprise a plurality of carbon nanotubes.
 11. The method of claim 1, wherein the ion-particle beam radiation has an energy greater than 50 eV.
 12. A nanoscale fiber film material comprising a plurality of nanoscale fibers, wherein the plurality of nanoscale fibers have been functionalized by a controlled irradiation process, wherein the nanoscale fiber film material has a thickness between 5 and 50 microns.
 13. The nanoscale fiber film material of claim 12, wherein the nanoscale fiber film material has increased tensile strength relative to that of a non-irradiated nanoscale fiber film material of the same construction.
 14. The nanoscale fiber film material of claim 12, wherein the nanoscale fiber film material has increased toughness relative to that of a non-irradiated nanoscale fiber film material of the same construction.
 15. The nanoscale fiber film material of claim 12, wherein the nanoscale fiber film material has increased electrical and thermal conductivity relative to that of a non-irradiated nanoscale fiber film material of the same construction.
 16. The nanoscale fiber film material of claim 12, comprising a plurality of cross-links, interconnections, junctions, or a combination thereof, between or among the plurality of nanoscale fibers.
 17. The nanoscale fiber film material of claim 12, wherein the plurality of nanoscale fibers comprise a plurality of carbon nanotubes. 